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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

ADEPT Sounding Rocket One Flight Test Overview

On September 12th 2018, a sounding rocket flight test was conducted on a mechanically-deployed atmospheric entry system known as the Adaptable Deployable Entry and Placement Technology (ADEPT). The purpose of the Sounding Rocket One (SR-1) test was to gather critical flight data for evaluating the vehicle's in-space deployment performance and supersonic stability. This flight test was a major milestone in a technology development campaign for Nano-ADEPT: the application of ADEPT for small secondary payloads. The test was conducted above White Sands Missile Range, New Mexico on a SpaceLoft XL rocket manufactured by UP Aerospace. This paper describes the system components, hardware development campaign, test execution, and test conclusions.

Cassell, Alan↗
NASA NTRS2019

ADEPT Sounding Rocket One Flight Test Overview

On September 12th, 2018, a sounding rocket flight test was conducted on a mechanically-deployed atmospheric entry system known as the Adaptable Deployable Entry and Placement Technology (ADEPT). The purpose of the Sounding Rocket One (SR-1) test was to gather critical flight data for evaluating the vehicle's in-space deployment performance and supersonic stability. This flight test was a major milestone in a technology development campaign for Nano-ADEPT: the application of ADEPT for small secondary payloads. The test was conducted above White Sands Missile Range, New Mexico on a SpaceLoft XL rocket manufactured by UP Aerospace. This paper describes the system components, hardware development campaign, test execution, and test conclusions.

Cassell, Alan M.↗
NASA NTRS2019

ADEPT Sounding Rocket One (SR-1) Flight Test

A sounding rocket flight test was conducted on a mechanically-deployed entry vehicle (DEV) known as the Adaptable Deployable Entry and Placement Technology (ADEPT). This flight test was a major milestone in a technology development campaign for ADEPT: the application of ADEPT for small secondary payloads. The test was conducted above White Sands Missile Range (WSMR), New Mexico on a SpaceLoft XL rocket on September 12, 2018. The first objective of the SR-1 flight test was to demonstrate that ADEPT could transform from a compact stowed configuration, separate from the launch vehicle, and successfully deploy exo-atmospherically into the desired low ballistic coefficient entry configuration. The second objective was to characterize the aerodynamic performance of the deployed configuration in order to evaluate the faceted blunt body geometry dynamic stability characteristics as it decelerated from supersonic to subsonic speeds.The ADEPT DEV had several sensors on-board and also leveraged third-party data sources for post-flight analysis and trajectory reconstruction. Based upon data review, the launch vehicle met exo-atmospheric delivery performance requirements of spin rate, no re-contact, separation velocity, and delivery altitude. The unique ADEPT forebody geometry (blunted octagonal pyramid, 0.7 m diameter at the rib tips) and aftbody configuration has never flown before. The forebody half cone angle at the ribs is 70 deg, while the half cone angle mid gore is 68.5 deg. The aftbody, where the 3U CubeSat 'payload' resides is a rectangular prism that extends ~ ½ the minimum forebody diameter behind the nose. Understanding DEV blunt body dynamic stability performance is critical for determining how they can be employed for atmospheric entry, descent and landing.The primary data products were used to perform flight mechanics analysis and reconstruct the as-flown trajectory. On-board video recovered post-flight demonstrated that the DEV achieved and maintained the desired entry configuration. Post-flight analyses showed that the vehicle met the threshold of achieving stable flight below Mach = 0.8. The ADEPT project has focused on ballistic, axisymmetric shapes as the logical 'first step' in mission infusion applications. With the current maturation and development of the ballistic (non-lifting) 1 m class ADEPT, the next step in ADEPT maturation is the focus on configurations that are capable of generating lift in order to accomplish aerocapture and precision landing mission capabilities. ADEPT is particularly attractive for evaluating various guidance and control approaches as the deployable structure enables attachment points for various actuation methods such as control surfaces, moving mass elements, or RCS thrusters. The ADEPT sounding rocket flight test provided a low-cost means of achieving significant system level maturity for the 1 m class ADEPT configuration. A description of the technology, system components, flight test execution, and conclusions will be described.

Cassell, Alan↗
NASA NTRS2019

Analysis of Bioreduction Strategies for a Solid Rocket Motor on an Interplanetary Mission to Europa

The Europa Lander De-Orbit stage braking motor must comply with the Planetary Protection requirements established for a category IV mission. In its mission to Europa, a motor that hasn’t gone through bioreduction environments will carry microbial spores and other biosignature molecules that might jeopardize a mission of astrobiological concern as well as future missions to come. A motor with solid rocket propellant represents exclusive challenges associated to the calculation of high numbers of an encapsulated bioburden hidden behind a nozzle plug. Existing techniques for bioburden reduction are analysed in perspective to motor assembly facilities and the series of events that are involved in manufacturing a solid rocket motor. These techniques include antimicrobial effects of chemical components already present within the motor and bioreduction due to assembly and operational environments induced in the motor. Analysis of the manufacturing process, adhered bioburden and recent investigations into the effectiveness of microbiological techniques in finding inherent antimicrobial properties have generated a step by step outline of Planetary Protection for lander mission associated solid rocket motors.

Velez-Justiniano, Yo-Ann↗
NASA NTRS2019

Extreme-Temperature Carbon- and Ceramic-Matrix Composite Nozzle Extensions for Liquid Rocket Engines

The United States (US) National Aeronautics and Space Administration (NASA) and its US industry partners are developing extreme-temperature composite nozzle extensions for a variety of cryogenic liquid rocket engine propulsion systems. Applications under consideration at the NASA Marshall Space Flight Center (MSFC) include launch vehicle (upper stage), in-space, and lunar lander descent/ascent propulsion systems. Composite material systems of interest include carbon-carbon (C-C) and carbon/silicon-carbide (C-SiC) composites, as well as modified versions of such composites (coatings, mixed matrices, oxidation inhibitors, etc.). Missions addressed include access to low Earth orbit, the lunar surface, and more distant destinations. Cryogenic upper-stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. As a result of the large size of such nozzles, and the related engine performance requirements, composite nozzle extensions are being considered to reduce mass impacts. Currently, metallic and foreign composite nozzle extensions used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles represent the state-of-the-art. Such extensions are limited to use at or slightly above 2000°F (1093°C). Materials under development by MSFC and its industry partners have the potential to operate at temperatures up to (or above) 4250°F (2343°C). Marshall Space Flight Center efforts are aimed at (a) further developing the technology and databases needed to enable the use of composite nozzle extensions on cryogenic liquid rocket engines, (b) developing and demonstrating low-cost capabilities for testing and qualifying such nozzle extensions, and (c) advancing the US domestic supply chain for nozzle extensions. Through the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Programs, low-level internal MSFC research projects, and teaming arrangements with domestic industry partners, composite material design, development, hot-fire test, and evaluation efforts are progressing. Hot- fire engine tests of subscale hardware have been conducted using oxygen/hydrogen (LOX/H2), oxygen/methane (LOX/CH4), and oxygen/kerosene (LOX/RP-1) propellants. These engine tests at MSFC have enabled the evaluation of both heritage and state-of-the-art material systems, demonstrating the initial capabilities of the extreme temperature materials and their fabrication methods. Recent, ongoing, and potential future work supporting cryogenic propulsion systems development will be presented. The composite nozzle extension technology and test capabilities being developed are intended to support both NASA and US Department of Defense requirements, as well as those of the broader Commercial Space industry.

Valentine, Peter G.↗
NASA NTRS2019

Additive Manufacturing of NASA HR-1 Material for Liquid Rocket Engine Component Applications

NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 was originally developed at NASA in the 1990’s and derived from JBK-75 to increase strength and ductility in high-pressure hydrogen environments. The NASA HR-1 chemistry was formulated to meet requirements for liquid rocket engine applications, specifically components used in a high-pressure hydrogen environment. Recent developments using additive manufacturing (AM) have made this material an attractive option for channel-cooled nozzles under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) program and other liquid rocket engine component applications. The RAMPT program has baselined to fully evolve and characterize NASA HR-1 material. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for channel-cooled nozzles in high heat flux environments. Initial development and characterization has been completed using blown powder Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF) additive manufacturing techniques to develop material test samples and nozzle hardware. NASA HR-1 powder has been sourced and characterized from several powder suppliers, and a series of development and hardware samples completed fabrication using DED and L-PBF. Characterization of the material has included heat treatment development, metallography, chemistry evaluations, mechanical testing, measurement of thermophysical properties, and fabrication of relevant nozzle hardware to demonstrate feasibility. This paper presents results from the process and early materials development and provide future development work including hardware fabrication.

Katsarelis, Colton↗
NASA NTRS2019

SmallSat missions enabled by paired low-thrust hybrid rocket and low-power long-life Hall thruster

The capabilities of a SmallSat-class spacecraft targeting the outer solar system and using a combined chemical and electric propulsion system are explored. The development of compact hybrid rockets has enabled high-thrust engines to be packaged tightly enough to fit on cubesat and SmallSat spacecraft. These hybrid rockets provide 10’s-100 N of thrust depending on the propellant load & >300 s of specific impulse and have been demonstrated in both ambient and vacuum environments. Advancements in low-power long-life Hall thruster technologies have provided the potential for significantly greater propellant throughputs, enabling their use as a primary propulsion element on interplanetary spacecraft. In a recent characterization test campaign, the MaSMi-DM Hall thruster demonstrated power throttling from 150 – 1000 W with >1500 s of specific impulse available at >500 W and >40% total thrust efficiency available at >300 W; peak values of 1940 s and 53% were observed. A notional low-mass spacecraft employing a combined hybrid rocket and low-power electric propulsion system was designed and used for mission concept analysis targeting the outer solar system. Using an imposed wet mass limit of 400 kg, mission trajectories to Saturn and Uranus were generated. Orbit capture with >40% of the launch mass was shown to be possible at either target, with mission transfer times of 7.5 years and 13.5 years for Saturn and Uranus, respectively. Significant follow-on mission activities near Saturn (e.g. to Titan & Enceladus) were also possible by carrying extra propellant mass while remaining under the total wet mass limit.

Karp, Ashley C.↗
NASA NTRSDate not supplied

A Review Towards the Design Optimization of High Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist with RDREs over CP engines such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), super-alloy materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major program goal is to rapidly produce ultra-high-performance AM injectors. This paper reviews the available literature on liquid rocket injector design optimization as well as the experimental work conducted to date on injectors tested in RDREs. Major lessons learned are document and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is discussed. Finally, several candidate AM RDRE injector elements were produced to obtain their diodicity and cold flow characteristics.

rotating detonation engine↗
NASA NTRSDate not supplied

Thermal Analysis of an In-Space Heat Shield Exposed to a Rocket Plume During Stage Separation

Thermal analyses were conducted to evaluate the thermal response of various individual materials and multi-layer configurations for an in-space heat shield exposed to a rocket plume during stage separation. Frequently used, readily available thermal protection materials consisting of cork, carbon cloth phenolic (CCP), and silica cloth phenolic (SCP) were selected for an initial screening analysis. SCP was chosen as the primary material for further evaluation using an updated thermal environment calculated using computational fluid dynamics (CFD) results. A multi-layer configuration consisting of SCP providing erosion resistance and a Nomex honeycomb providing thermal protection was then evaluated as a solution for more mass-efficient performance. Pyrolysis depth, bondline temperature, back-side temperature, and a thermal factor of safety were used to define the necessary material thickness profile. Adhesives were included in the analyses with considerations for maximum temperature and application method. One dimensional thermal analyses at several stations along the heat shield surface were performed for the initial screening and follow-on analyses. The methodology used standard processes and computer programs applicable to solid rocket motor internal insulation and nozzle thermal analysis such as Chemical Equilibrium and Applications (CEA), Aerotherm Chemical Equilibrium (ACE), Momentum/Energy Integral Technique (MEIT), and Insulation Thermal Response and Ablation Code (ITRAC). The baseline SCP/Nomex honeycomb multi-layer configuration thermal performance predictions satisfied the objectives with an acceptable mass estimate for the design maturity. The EA9673 film adhesive and SCP resin were the best performing bonding agents considered for the SCP/Nomex honeycomb and Nomex honeycomb/structural substrate interfaces. The baseline mass estimate was lowest when the resin was the bonding agent due to the higher maximum service temperature. These thermal analyses evaluated typical internal and external nozzle materials using a calculated thermal environment and heat loads that were lower than a typical rocket motor internal environment but greater than standard external aeroheating.

Andrew T Hiatt↗
NASA NTRSDate not supplied

An Updated Model for the Effect of Atmospheric Absorption on Sounding Rockets

A very high-resolution R > 20,000 Far Ultraviolet full-disk, solar spectrograph will be launched in the Spring of 2023. This paper describes the in-flight wavelength calibration techniques and the fortuitous retrieval of Earth’s thermospheric information during the flight. Building and calibration of the Full-sun Ultraviolet Rocket Spectrograph (FURST) is currently underway. The purpose of this instrument is to obtain the highest resolution and most complete Far Ultra-Violet (FUV) spectra of the full disk Sun. This so-called "Sun-as-a-star" spectra will allow direct comparisons between our Sun and other stars measured by the Hubble Space Telescope(HST) and the upcoming James Webb Space Telescope (JWST). The Solar Physics groups at NASA Marshall Space Flight Center (MSFC) and Montana State University (MSU) have been developing the tools and procedures necessary to achieve the high spectral resolution goal. These include, among other things, improved tracking of error propagation, in-situ monitoring of the camera gain with a radioactive Fe-55 source, and the development of a simulated spectral calibration map under a noisy diagnostic-lamp signal. This mapping introduces a clocked CCD in order to obtain sub-pixel spectral resolution and overcome the Nyquist limit by about a factor of 2. Aside from the main purpose of FURST, we have been investigating the effect of absorption in the upper atmosphere at sounding-rocket altitudes (about 100-300 km). We present here an improved model of the optical depth caused by the thermospheric Oxygen cross-section and H and O self-absorption. This data-based model uses concentric spherical shells to account for the curvature of the Earth’s atmosphere and refraction. Using these calculations, we present the anticipated effect on the signal received by FURST, how that signal changes over the course of the flight-path These absorption peaks would provide wavelength fiducials at line-center that might add to in-flight calibration of the instrument. Many studies have found ways to correct for these so-called "Telluric" lines. However, it may be that these lines can in fact be a useful tool to further improve our calibration, rather than simply a nuisance to be corrected for! Finally, we discuss the inversion problem: how we could take actual flight data and back-out the atmospheric data (such as density and temperature) from any such sounding rocket flight that shows evidence of atmospheric absorption.

Nicolas Donders↗
NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

NASA's Compact High-Efficiency Rotating Detonation Rocket Engine for Mars Interplanetary Missions

NASA has successfully test fired a novel and compact liquid propulsion system known as a Rotating Detonation Rocket Engine. This is a specially designed ring-shaped thrust chamber that leverages additive manufacturing techniques and novel alloys such as GRCop-42 and GRX-810. The extreme combustion event, known as a detonation, reduces the combustion chamber length requirements down to a few inches while equivalent constant pressure rocket thrust chambers are on the order of feet. This is primarily due to rapid completion of combustion by the high-pressure detonation, an order of magnitude faster than deflagration combustion. In addition, the ring shape allows for rapid expansion of the combustion products. Depending on the thrust class and design supersonic area ratio, the full RDRE can be anywhere from 10% to 50% shorter than a traditional liquid rocket assuming the same exit diameter but is dependent on a number of design assumptions. This may enable substantial mass savings, cost savings, and broader design trade space for various mission architectures. Finally, the engine system has potential for higher Isp at identical average chamber pressure, which is currently being assessed by NASA. Experimental data obtained from testing in 2022 identified the feasibility of the novel propulsion system while multiple test series scheduled throughout 2023 and 2024 target closing the remaining critical technical gaps preventing widespread use of the technology amongst industry.

Thomas Teasley↗
DOE OSTI2021

Planned Steady State Irradiation of Characterized Instruments for Nuclear Thermal Rockets Using In-Pile Experiment Apparatus

The development of nuclear rocket technology is critical for the further exploration of extraterrestrial bodies. Nuclear rockets are capable of providing various advantages over current chemical rockets. However, the harsh environment provides a number of challenges regarding instrument performance. Temperature extremes, radiation (reactor and space), and the inability to conduct traditional maintenance activities can lead to a severe degradation in instrument performance. To better understand the effects of radiation on instrumentation, an irradiation campaign has been designed to test a set of instruments provided by a collaborator in the aerospace industry. Details concerning pre-irradiation performance are provided for a future comparison to the irradiated performance. Additionally, the design of the irradiation test is described in detail.

Floyd, Dan↗
NASA NTRS1964

Rocket-motor spin-test apparatus

Rocket motor spin test apparatus capable of subjecting solid rocket motors to dynamic spin or roll environments encountered in flight

FLIGHT TEST INSTRUMENT↗
NASA NTRS1966

Rocket propagation experiment

Electron densities and collision frequencies from Nike-Apache rocket firings, results of eclipse experiment in South America, and instrumentation for rocket propagation studies

ELECTRON DENSITY↗
NASA NTRS1953

Experimental investigation of a lightweight rocket chamber

Experiments have been conducted with a jacketed rocket combustion chamber that was fabricated by hydraulic-forming from sheet metal. Rocket combustion chambers made by this method have been used successfully. Runs with these combustion chambers have been made at over-all heat-transfer rates 1.7 Btu per square inch per second with water cooling and also ammonia as a regenerative coolant.

ENGINES, ROCKET↗
NASA NTRSDate not supplied

Advanced and Additive Manufacturing Technologies for Liquid Rocket Engine Components

Overview of advanced manufacturing and additive manufacturing development at NASA for liquid rocket engines. Presentation includes various material, process, design, and hot-fire testing developments demonstrating the use of advanced components for liquid rocket engines on launch vehicles and in-space systems.

Additive Manufacturing↗